Preformed product and method of making same



Aug. 18, 1936. H. 1.. ROGERS 2,051,532

PREF'ORMED PRODUCT AND METHOD 0F MAKING SAME Filed March 26, 1931 I 2 She ts-Sheet 1 Aug. 18, 1936. H. 1. ROGERS 2,051,532 PREFORMED PRODUCT AND METHOD OF MAKING SAME Filed March 26, 1931 2 Sheets-Sheet 2 Patented Aug. 18, 1936 UNITED STATES PATENT ,oFiFlcE PREFORMED PRODUCT AND METHOD OF MAKING SAME Homer L. Rogers, Dayton, Ohio, assignor to Johns-Manville Corporation, New York, N; Y.; a corporation of New York Application March 26, 1931, SerialNo. 525,372

2 Claims.

This invention relates to a method of manufacture of and to preformed or premolded products of bituminous or asphaltic compositions, having properties which render-them suitable for various structural uses,-as for flooring, bridge planking, fence posts, and the like. The purposes for which these products -may be employed are limited by the propertie's required for different applications or installations thereof. In some cases the product must be resistant to heat and yet 'non -brittleat relatively 110w temperatures.

Tensile strength as well as toughness and stability are frequently important. It is highly desirable that these products should to some appreciable extent at least be resilient andcflexible and capable of distortion or bending without undergoing permanent deformation. For some purposes :the products must be capable of withstanding repeated :impacts or live loads such as those to which bridge flooring is subjected. Moreover-the utility of a preformed product is considerably increased when its composition is such that a'nail forexamplemay be'driven into or through the same, especially at relatively low temperatures. In many instances the Weight must be maintainedata-minimum without sacmaking products of this kind; to improve the workability of the mix'from whichthe products are formed; and also to improve the composition of products of this class so .as to reduce the wear on forming apparatus as well as to reduce the-,powerrequired for such operations.

In the drawings: 7

Figs. 1 and 1 when taken togetherin end-toend relation constitute a diagrammatic .plan view of apparatus for making a preformed product; and I Figs. 2 and 2 when similarly arranged are a diagrammatic side elevation of the apparatus shown in Figs. 1 and 1 In accordance with the present invention, the principal ingredients of a composition of this general class may comprise bitumen or asphalt, a mineral or organic filler and a binder, preferably of dry fiber, such as Wood fiber, rag fiber, burlap fuzz,'cocoanut, sisal, tampico or similar fiber having-good tensile strength. These products may be made from virgin materials or from asphaltroofingscrap-for example to which prove the character ofthe product.

an appropriate amountof dry fiber may be .added should-the latter be desired. In vmany products of this general character the property of hardness, .in the sense in which that :term is .used .to describe sheet-asphalt or other bituminous pavements, isnot so important as -it.=is that the prodnot should have toughness and stability and be form retaining. Efforts have been made to produce asphalt bridge planking, for examplafcontaining high percentages of mineral .matter .for

"the purpose of obtaining hardness inthe sense that this term is used in describing sheet :as phalt,-but these efforts have been unsuccessful because it is impractical .to introduce into a fibrous, bituminous mass sufficient mineral filler :l o

to obtain contact between-the mineralparticles. The mineral filler in all types of asphalt plank,

which is representative ofproductsof this generalclass, is in suspension and the trafllc supprimarily upon mineral matter. :In sheet asphalt the mineral filler supportsthe load, .for the mineral particles are .in contact, :the interstices between the mineral particles being .=filled with bitumen which acts as a binder .for .the; mass. 'l he use of a large amount-of .mineral filler in --a' bridge -plank or 1 similar preformed product causes the plank to be brittle soithat it is difficult to drive nails through it without splitting the plank;particularly along the edges thereof. In some instancessuch planksztendto crack anddisintegrate under traffic and .it will be apparent =that a=brittle plank of this-ltype is very difficult to handle and toapply. In preformed products in accordance withlthis .invention the bitumen or asphalt is reinforced with fiber and the performance of such products .is

due tosome extent to the-pr.esence.of .fiber in thecQmpoSition. A finelydivided mineral .filler ofa cellular 'nature, such as diatomaceous iearth, may be used without fear of destroying, the

fibrous nature of the premoulded material and adversely afie'cting stre'ngth' and brittleness.

Furthermore, if the filler .is -of an absorbent nature it will tend toincrease the-melting point of the asphalt and thereby render it less .susceptible to temperature changes. lttha's been found that diatomaceo'us earth is admirably suited to function as-a fillerforproducts of this kind.

porting ability of the plank does not depend In general any diatoma'ceous earth ..willim- Typically celite is preferable as this earth.

While the primary-action. of "Cfelite inabituminous mixtures is essentiallythesame .asethatjof any mineral filler, yet-because of itspeculiar structure Celite shows a {larger .volume:for .a

inactive mineral fillers is directly related to the area of the surface presented to the bitumen,

and is merely a wetting of the filler by the bitumen. Ihe thinner the film of bitumen, the less now there will be as the temperature increases.

In the Celite mixture the bitumen is distributed over a larger area of the filler thanin the case of a round-particled filler of equal weight and V smallervolume, thereby reducing the film thickness of the bitumen and subsequently decreasing the liability to fiow. As the melting point of a bitumen filler mixture'depends upon the readiness with which it"will fiow'it will be seen that the Celite mixture will have a higher melting point. An important advantage derived from the use of Celite in such mixtures as preformed planks, battery boxes and the like, is that less weight of material is required to produce the stabilization desired. Reduction of weight is of considerable importance, particularly in bridge flooring since asphalt plank for example involves a considerable; tonnage and there is a material saving in freight, but of still greater importance 1 is the reduction of the dead loadon the bridge.

. Dueto its porous cellular structure Celite also gives added mechanical protection to the bitumen, rendering it ,opaque to the disintegrating light rays. .sents a considerably larger surface as a pro- Celite because of its structure pretector andhence proves more desirable when considered on an equal weight basis.

Other. advantages of Celite in premolded asphalt are its low apparent density, chemical purity, highabsorptivecapacity, and comparatively large surface area. In all ofthese respects Celite-differs from ordinary inorganic fillers ineluding most other commercial diatomaceous earths. These particular properties'of Celite are attributed to the heterogeneity of diatom forms, "the absence of any large amount of clay or crystal impurities; and to the open cellular structure of the individual diatom particles making upithe whole; highly porous cellular structure accounts for the high absorptive nature of Celite .and together with the. particle size distributionof the powder, accounts for its light weight. "Celite particles are anisotropic in form, the individual particles varying from long needlelike bodiesto fiat disk-shaped forms'with many intermediate shapes. The size of these various forms differs considerably and the net result of Without attempting to correlate completely the physical properties of diatomaceous earths with their value in .asphaltic or bituminous compositions itmay be said-in general that light weight and porosity are an advantage and that a dense compacted earth made up of small cylindrical diatoms is inferior to a light fluffy earth composed of larger and more spicular forms.

In the manufacture of preformed or premolded products asphalt roofing scrap or any asphalt and fiber mixture are partiallyimasticated and the desired percentage of finely divided fossiliferous filler or diatomaceous earth, preferably Celite is added and thoroughly distributed throughout the mass. It has been found that the use of 'anexcessive amount of. fine mineral filler of the non-cellular types, such as talc, fine sand and similar finely divided materials tends to reduce the mechanical strength of the product. The Celite powder or other finely divided cellular filler is substituted for all or at least a portion of the finely divided non-cellular materials as heretofore used in products of this character, but coarser mineral, such as particles of slate, limestone and/or ground cinders may be used. For a general classification, those fillers which are retained by a 48-mesh screen may be classed as coarse fillers and those which pass through this screen may be considered the finely divided fillers, although, of course, it will be understood that this line .of demarcation is merely an approximate arbitrary value which may be varied considerably and is given here only for the purpose of pointing out in general the relative. grades which are to be selected. Preferably the ratio of coarse mineral filler to fine fossiliferous or cellular filler ismaintained at a ratio of at least 1 to 1, but here again it will be understood that satisfactory products may be obtained even though this ratio is varied considerably. Entirely satisfactory products may be and in fact have been obtained with as little as 5% Celite but preferably the percentage of this material should be. approximately 6 to 7 or '7 /2% with 92 /2% to 94% asphalt roofing scrap,

although only 70% or even less of the latter material may be used for there is a great degree of latitude in formulas for products of this character. variety of types of this material which is ob- The asphalt roofing scrap may be of'a tainable from various roofing 'manufacturers.

It consists of asphalt saturated rag felt, asphalt saturated and asphalt coated rag felt and asphalt saturated, asphalt coated and mineral surfaced rag felt. Any one, or a combination of all, or of any two of the kinds described may be used. For

the roofing scrap equivalent quantities of asphalt, and fiber or asphalt, mineral and fiber may be used should the product be made entirely from virginmaterials. The amount of asphalt of bitumen in these products may vary from around 35 V to approximately 60%, and for bridge flooring .very 'goodresults are obtained from a mixture approximately 53% bitumen, 17% organic fiber,

. 19% coarse mineral and 11% fine mineral.

Apparatus for manufacturing this material as shown in the drawings may comprise a preheater in the form of a rotary cylinder l0 having cone-shaped ends lland l2. This cylinder has in its side wall, a charging opening 13' which is closed by a removable closure member I3. The ends of the cylinder are open at M and I6. For the purpose of heating material in this preheater there is provided a duct H which registers with the opening l4, and a means for producing; a forced draught through the cylinder comprising, in the present instance, a fan I8 adapted to be driven by a motor orthe like I9 is arranged adjacent the opening H5 at the opposite end of the cylinder. The conical ends of this cylinder are provided with circumferential tracks or rails 2|, whichrrest upon spaced rollers 22 mounted upon the foundation structure 23. For rotating the cylinder there is provided an individual drive unit'comprising an 7 electric motor 24, which is connected to a speedreducing mechanism 26. The latter operates a driving pulley 21 and a belt 28 is trained around the driving pulley and around a pulley 29 on the conical end of the cylinder. The foundation structure 23 is preferably in the form of trans verse blocks or supports 30 which extend only under the end portions of the cylinder.

An endless conveyor belt 3| is arranged to operate under the intermediate portion of the cylinder between the supports 30, This traveling conveyoralso operates upwardly in an ininclined direction as shown in Fig. 2, and is equipped with Sideboards 32; for guiding material thereon. A chute 33 is arranged for receiving material from the upper end of the conveyor and for directing this material into a stea mjacketed masticator and mixer 34. This mixer is mounted to pivot at 36, so that the contents er may be seharsedi to a e mac ted hopper 31. This hopper is provided with a removable closure member or'door (not shown) in the lower portion thereof, so that the 0on tents of the hopper may be discharged as desired upon a traveling belt or conveyor 38, which is adapted to be driven by an individual drive unit comprising a driving motor 39, and speedreducing mechanism 4|. Platforms 40 and 40' a r id d; r mttsn a is 1 M 14? is positioned to receive material from thev endof the conveyor 38; and is. inclined downwardly. to discharge such material into the hopper 43 of an extruding machine indicated generally at 44, so that the. extrusion is made promptly.

This extruding machine 'is in the form of a standard pug mill used in the clay industry, having a spiral screw or auger, which operates in a cylinder to force material from the hopper hrqus difi- 9 ext dsr d i e t m,- able speeds by means of an apparatus comprising a driving motor 46 and variable speed mechanism preferably a Reeves drive 4'! and a mechanical drive 48 for transmitting power to a driven shaft 49, which operates through mechanism (not shown) to actuate the auger of the machine. Variable speed is highly desirable for extruding products of different sizes, as planking of different cross-sections. The extruder is also equipped with a steam-jacketedv forming die 46, which is of the proper configuration to give the desired contour to products being extruded therethrough. The steam-heated. die prevents gumming of asphalt at the die opening.

An endless conveyor 5| (Figs. 1% and 2 is disposed in a cooling tank 52 and arranged to receive extruded products issuingfrornv the die of the extruder. A perforated spray pipe. 53 is disposed longitudinally above the conveyor for discharging a spray of water or other cooling fluid upon the products carried thereby. As shown in the drawings this spray pipe is supplied with cooling water from a connection 54, which is connected by means of a T 55 with supply pipes 51 and 58. Preferably valves '59 and 6! are interposed in these pipes adjacent to the T. The pipe 51 is connected to the city water supply system or other source of, pressure supply. The pipe 58 is connected to water supply tanks 62 and 63' by means of connections 64 and 66. A discharge connection 61 extends through the cooling tank 52 to a point near the preferred water level thereof, and is adapted to discharge water from this tank to the well or sump 68. A suitable pump, such as the centrifugal pump 59, has its inlet ll. connected to the sump 68, and its discharge connection 12 arranged to convey water to one of the tanks as to he tank 63., a shown.

At the discharge end of the conveyor 5|, adjustable upper and lower cylindrical calendar rolls l3 and 14 are arranged to receive a preformed. d t, s? e trud 1 a *9 reduce it tothe proper size.- Adjustable i6, 16' are arranged to engage, the side walls of a column at this pointtocooperate with the calender rolls in ironing outthe irregularitiesfin the surface of the column, and "also in reducing it, so as .to overcome any tendency of the column to swell'after. release of the pressuredeveloped in. the extruding machine. I

A receiving table 11 is arranged to receive extruded products from the calender. rolls. A traveling cut-oftsaw 18 is mounted for move? ment longitudinally of this. table. saw is preferably, inv the form of a rotary cutter 19 whichis operated by, a, driving motor 8 sting through speed change mechamsrn 82, to oper ate abelt or the like 83 which is trained over a pulley fast on the shaft onwhich the rotary cutteris mounted. This mechanism is mounted upon a carriage. 84 whichis proyidedwith supporting wheels 86 operating on tracks. 8-1, extending substantially parallel to a direction of motion of products discharged by the calender rolls. An adjustalolev abutment or stop 88 is mounted upon a fixed rod 83 and, adapted to be secu ed in difi rent positio s o itudinal y thereof by means of a set screw 91. This stop is positioned to engage the end of a column'or other product to'det'ermine the length at. which it is to be cut by thesaw. The carriage 8.4; of H the saw maybe provided, with a handle, 92 by which this. carriage may ,be, moved manually along the tracks 8]. v

In Operatiml. of fi p a i ai 9 5. 5 E 41? or equivalent quantities of virgin materialsfmay be fed in. measured quantitiesinto. the preheater Ill through the charging. opening l3 in' the side wall thereof, where it is heated and partially oken up, h at eing sup ied fr m ai d awn through'the duct 11' from the stack or other source of hot air. The temperature of the stock is raised from 40 to 50? above atmosphere in this 'preheater. The preheated, stock is. then discharged onto the-co-nveyor 3! by removing. the door !3 from the side wall. The belt'conveyor carries the stock to the chute 33, which dis; charges it into the mixer and. masticator 34. As the stock is delivered into'this mixer powdered fossiliferous material, preferably, Celite. is added in quantities closely approximating the amount required to produce the desired composition and the temperature of. themasticated stock is raised to 150 i F. to 300 F., preferably to approximately 250 F. The stock remains'in this mixer until it is reduced to finely divided particles, that is, to a condition in which the felt or otherbinder has been torn apart, or fiberized, and intimately mixed with the mineral matter and. asphalt, In this condition the heated mass, tendsto stick or cling together and is in such form that it would not readily discharge from the tank of the mixer as this tank is elevated to a vertical or slightlygreater position. I

In order to facilitate the discharge of this material from the mixer, a slight additional charge of Celite is added to cause the mass to break up into balls, in which condition it is readily discharged into the capacity hopper by causing the mixer to swin about its pivotal axis 36.

The remnants of the mix. may be pulled out ofthe mixer by hoe or similar tool, should this, be ces y The tem e ture. of the stock is maintained from 150 to 300 F., preferably at substantially 200 F. in the capacity hopper, the

stock being raked or otherwise removed from "this hopper, as desired, onto the conveyor as,

which discharges ,the stock into the chute 42 of the extruding machine.

As a column, for example, is formed by this machine, it is received by the submerged conveyor 5| which carries it und'er'the water sprays provided by the spray pipe 53, and also partially submerges the column in the water .of the tank 52. The spraysand submergencerapidly chill the column while it travels the length of the tank, Upon reaching the end of'the tank, the product passes through the calender rolls 13, H and between the disks [6, 16, all of which are adjusted to provide any given cross section. After passing through these rolls, the product passes onto the table 11, where it is cut to desired lengths by the rotary cutter 18. -Following this, :the products, such as planks or slabs, are du'stedwith sand, talc, or other non-adhesive agents; thereby completing the manufacturing operation.

'Theeffect of Celite on a fibrous bituminous composition is to cause a hardening of the prod-'- uct. Immediately after manufacture there is free asphalt in excess of that absorbed upon the fibres or, superficially, upon "the Celite and. 'minute light colored particles or pockets of Celite *may be seen in the mass, but in the course of a few weeks these disappear, indicating that the Celite is. absorbing asphalt. About a week after 'manufacture these small pockets of Celite change in color from practically white to a deep yellowe This change continuesuntil at the end of ap-.

proximately 30' days it is impossible to detect the small pockets of Celite and the composition is jet black throughout its entirety indicating that the Celite has absorbed a considerableamount of oil, Further, proof that such is the case is found in the fact that a product 90 days,

, general and specifically Celite are effective to reduce the amount of free asphalt in the mixture and cause the'product ,to become more resistant to heat, 'more stable and less brittle. Celite also dries the mix so that the surface of an extruded product is rough and as practically all of the free oil is absorbed the surfaces of these products are 'not sticky as heretofore but are sensibly dry even in warm weather. Furthermore these planks maybe nailed at temperatures as low as 32 F. which meets all practical requirements and makes it possible to apply planks or' the like during the winter season. It will be seen that this is a decided advantage when it is realized that previous products of 7 this during warm weather the joints between the slabs usually disappear. Practical experience has proved that the use of Celite asphalt plank for instance produces a tougher material, less susceptible to temperature changes, and which is less brittle at low temperatures and which marks under various objects such as horse shoes, tractor treads, etc., to no ob'jectionable degree.

Asphalt plank when made in accordance with this invention is particularly suitable for bridge flooring as it fills a need for a material that will accommodate itself to constant vibration and movement, will not corrugate and will'knit and heal under trafiic, as this product has the ability to recover its shape after itis dented.

In addition to improving quality of the product Celite or other diatomaceous earth havin creases the workability of the mix in an extruding machine'a'nd in addition causes less wear than heavier and coarser mineral matter and makes it possible to perform the necessary forma ing or molding operations with less power.

latter with less friction than other diatomaceous' earths. The peculiar porous cellular structure tends to facilitate fiow of the relatively thin film of the mix,gso that less power is required to extrude or otherwise'work' the material.

It should be understood that the present disclosure is for the purpose of illustration only and that this invention includes all modifications and equivalents which fall'within the scope of the appended claims.

I claim:

' of bitumen and" thus improves the workability 1."I'he methodof making a preformed unit which comprises mixing bituminous material and fibrous reenforcement therefor at an ele- 'vated temperature until the resulting mass is partially broken up,'then adding finely divided diator'naceous earth'in amount corresponding to approximately 5 to 7% of thesaid mass, continuing the mixing until the resulting product with the said bituminous material, whereby the stiffness of the mass at a ven temperature is increased subsequent to the extrusion.

2. A preformed flooring plank comprising a compressed mass including a large proportion'of bituminous material of the typ of asphalt, reenforcing fibers dispersed throughout the said bituminous material, and admixed finelydivided 35 diatomaceous earth in the proportion of approximately'5 to '7 parts by weight to 100 parts of total weight, the'diatomaceous earth serving to absorb excess free oil and causing the plank to be tough and form-retaining at elevated temperatures but not brittle. at low temperatures.

HOMER L. ROGERS. 

